Method and apparatus for dispensing solid product

ABSTRACT

A dispensing system includes a dispenser, a logic device, a nozzle, a diluent source, and a solid product. The logic device controls spray on and spray off cycles to pulse diluent supplied to the nozzle. The diluent contacts the solid product to dissolve a portion of the solid product and create a use solution. Pulsing the spray of diluent controls the concentration of the dispensed product in the use solution by limiting the amount of excess dilutant added to the dispensed product. The product is more consistently dispensed and the concentration of the dispensed product in the use solution is more consistent. Additionally, the concentration of the dispensed product in the use solution can be controlled by changing at least one of a volume of diluent dispensed through the nozzle, a pressure of diluent, a pulsed diluent spray frequency, and a pulsed diluent spray duration.

This application claims the benefit of U.S. Provisional Application No.61/156,962, filed Mar. 3, 2009.

FIELD OF THE INVENTION

The present invention relates to a method and an apparatus fordispensing a solid product.

BACKGROUND

A solid product is commonly converted into a concentrated solution or ause solution by dissolving at least a portion of the solid product byimpingement of a diluent, such as water, upon the solid product.Examples of such solid products include pre-rinse products, enzymes,detergents, rinse aids, and other products. Maintaining the required ordesired concentration of the resulting concentrated solution or usesolution over several cycles can be a challenge.

For the reasons stated above and for other reasons stated below, whichwill become apparent to those skilled in the art upon reading andunderstanding the present specification, there is a need in the art fora method and apparatus for dispensing solid products consistently tomaintain required or desired concentrations of the resultingconcentrated solution or use solution over several cycles.

SUMMARY

The above-mentioned problems associated with prior devices are addressedby embodiments of the present invention and will be understood byreading and understanding the present specification. The followingsummary is made by way of example and not by way of limitation. It ismerely provided to aid the reader in understanding some of the aspectsof the invention.

In one embodiment, a dispensing system comprises a dispenser including acavity and a nozzle, a solid product positioned within the cavity, adiluent source in fluid communication with the dispenser supplying adiluent to the nozzle, and a logic device controlling spray on and sprayoff cycles to pulse the diluent supplied to the nozzle as a pulseddiluent spray during a product dispensing process. The diluent contactsa surface of the solid product to dissolve at least a portion of thesolid product and create a use solution. The pulsed diluent sprayincreases the concentration of the dissolved solid product in the usesolution by limiting an amount of excess diluent in the use solutionduring the product dispensing process.

In another embodiment, a dispensing system comprises a dispenserincluding a cavity and a nozzle, a solid product positioned within thecavity, a diluent source in fluid communication with the dispensersupplying a diluent to the nozzle, and a logic device controlling sprayon and spray off cycles to pulse the diluent supplied to the nozzle as apulsed diluent spray during a product dispensing process. The diluentcontacts a surface of the solid product to dissolve at least a portionof the solid product and create a use solution. The pulsed diluent sprayincreases the concentration of the dissolved solid product in the usesolution by limiting an amount of excess diluent in the use solutionduring the product dispensing process. The concentration of thedissolved solid product in the use solution is approximately 3.0 to10.0% by weight of the use solution and the solid product is selectedfrom the group consisting of a solid enzyme product, a solid neutralproduct, a solid alkaline product, and a solid acid product.

In another embodiment, a method of dispensing a solid product comprisesplacing a solid product in a cavity of a dispenser having a nozzle influid communication with a diluent source, the diluent source supplyinga diluent to the nozzle, pulsing the diluent onto a surface of the solidproduct as a pulsed diluent spray to dissolve a portion of the solidproduct and create a use solution during a product dispensing process,wherein the pulsed diluent spray increases a concentration of thedissolved solid product in the use solution by limiting an amount ofexcess diluent in the use solution during the product dispensingprocess.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention can be more easily understood, and furtheradvantages and uses thereof can be more readily apparent, whenconsidered in view of the detailed description and the following Figuresin which:

FIG. 1 is a schematic block diagram of a dispensing system constructedaccording to the principles of the present invention;

FIG. 2 is a side elevational and exploded view of the dispenser of FIG.1;

FIG. 3 is a schematic block diagram of another embodiment dispensingsystem constructed according to the principles of the present invention;

FIG. 4 is an embodiment of a suitable wiring diagram for the dispensingsystem shown in FIG. 3;

FIG. 5 is a pictorial representation of dispenser settings (diluentspray on and spray off times) used in a Design of Experiments (“DOE”);

FIG. 6 shows dispensing profiles from the DOE of FIG. 5;

FIG. 7 is a graph showing the average effects of spray on time and sprayoff (delay) time using the averages of the dispensing profiles of FIG.6; and

FIG. 8 shows the sump concentration of a dispensed portion of solidproduct by weight of the use solution in the sump for a pulse controlledspray and an uncontrolled spray.

In accordance with common practice, the various described features arenot drawn to scale but are drawn to emphasize specific features relevantto the present invention. Reference characters denote like elementsthroughout the Figures and the text.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

In the following detailed description, reference is made to theaccompanying drawings, which faun a part hereof, and in which is shownby way of illustration embodiments in which the inventions may bepracticed. These embodiments are described in sufficient detail toenable those skilled in the art to practice the invention, and it is tobe understood that other embodiments may be utilized and mechanical orelectrical changes may be made without departing from the spirit andscope of the present invention. The following detailed description is,therefore, not to be taken in a limiting sense, and the scope of thepresent invention is defined only by the claims and equivalents thereof.

The term “concentrated solution” means a solution comprising a diluentand at least a portion of a solid product that could be further dilutedor used in its relatively concentrated form as a use solution withoutfurther dilution. The term “use solution” means a solution comprising adiluent and at least a portion of a solid product that is used withoutfurther dilution. The diluent could be one or more diluents. Althoughthese terms “concentrated solution” and “use solution” are usedthroughout the description, it is understood that these solutions couldbe interchanged depending upon the type of product being used and theintended use of the product. For example, a use solution could be usedwithout further dilution or it could be further diluted prior to use.Thus, the recitation of one type of solution does not limit the use tothat type of solution.

One embodiment utilizes a solid product dispenser including a logicdevice, which controls the spray cycle, and a relatively low flow spraynozzle. Examples of dispensers that could be used are the ASEPTI-Solidand OptiPro dispensers by Ecolab Inc. and the dispensers disclosed inU.S. Pat. Nos. 4,690,305; 5,100,032; and 5,417,233; which are herebyincorporated by reference herein. These and other types of suitabledispensers could be modified to include a suitable logic device and asuitable nozzle.

In one embodiment, a dispensing system includes a dispenser, a logicdevice, a nozzle, a diluent source, and a solid product. The logicdevice controls spray on and spray off cycles to pulse the diluentsupplied to the nozzle, which then contacts the solid product todissolve a portion of the solid product and create a use solution duringthe product dispensing process.

It is thought that pulsing the spray of diluent during the productdispensing process controls the concentration of the dispensed productin the use solution by limiting the amount of excess diluent added tothe dispensed product. The product is then more consistently dispensedand the concentration of the product in the use solution is moreconsistent. Additionally, the concentration of the dispensed product inthe use solution can be controlled by changing at least one of a volumeof diluent dispensed through the nozzle, a pressure of diluent, a pulseddiluent spray frequency, and a pulsed diluent spray duration.

For a solid enzyme product, one embodiment, which is shown in FIG. 8,enabled the ability to increase the concentration of the dispensedproduct in the dispenser's sump from approximately 2.50% toapproximately 3.75% by weight of the use solution by utilizing pulsedspray of a diluent onto the solid product versus a non-pulsed spray.Further, this embodiment enabled the ability to target specificconcentrations in the range from 3.0 to 10.0% of dispensed product inthe dispenser's sump by adjusting the pulsed spray frequency andduration. It is recognized that the percentage of dispensed product inthe use solution could vary depending upon the type of solid product.Among other variables, the diluent spray duration, also referred to asspray on time, and diluent spray frequency, also referred to as sprayoff time, (the pulsed spray of diluent on and off) are variables incontrolling the concentration of dispensed product in the dispenser'ssump and providing a consistent dosing of product.

An example solid product dispenser is shown in FIGS. 1 and 2. Adispensing system 10 has a housing 11 with an upper storage portion 12for holding a solid product 65, as best seen in FIG. 2. Several blocksof solid product 65 may be placed within the upper storage portion 12.FIG. 2 illustrates two blocks 65 a and 65 b. A cover 13 extends acrossthe upper end of the storage portion 12 to provide access to the cavitywithin the storage portion 12. At the lower end of the housing 11 is acollector portion 14. The lower end of the collector portion 14 definesan outlet port 15 for passage therethrough of solution collected bycollector portion 14. Conduit 18 extends from the outlet port 15 toterminate at a position directly overlying the reservoir 17. The outletport 15 directs the solution downwardly as illustrated by the arrow 82by gravity. If the solution is not fed by gravity, a solution pump (notshown) could be provided in the outlet conduit 18.

A diluent supply inlet conduit 19 is connected to the housing 11 and isin fluid communication therewith for providing a source of diluent flowto a spray-forming nozzle 20. The nozzle 20 directs diluent, such aswater, upwardly as shown by the arrow 21 in FIG. 1 so as to impinge uponthe block of solid product 65 and dissolve at least a portion of thesolid product, at which time the resulting liquid solution descendsthrough the collector portion 14 as shown by the arrow 22 in FIG. 1.Control of the dispensing of the solution from the housing 11 is done bycontrolling the flow and the amount of diluent to nozzle 20, which maybe done in a number of ways including mechanical means such as hydraulictimer valves and electrical means such as electrical switching in thecontrol system (not shown) of the utilization vehicle 23 (i.e., a warewashing machine, washing machine, etc.).

The solid product 65 could be a pre-rinse product, an enzyme product, adetergent product, a rinse aid product, or any other suitable productthat is dissolved at least partially by a diluent to create aconcentrated solution added to a diluent line at mixer 24 to create ause solution. Thereafter, supply conduit 16 carries the diluent and theconcentrated solution mixed to form a use solution to utilization point23. Also located at mixer 24 is a pressure switch (not shown), whichmonitors the pressure of the diluent being delivered to utilizationpoint 23. The pressure switch closes when diluent is being delivered.Therefore, the dispensing system 10 only operates when the use solutionis required at the utilization point 23. Those skilled in the art willappreciate that other time periods for operation may be desired.

The concentrated solution 25 is collected within the reservoir 17 whereit is available for use when necessary by the utilization vehicle 23.Supply conduit 16 transports the concentrated solution to theutilization vehicle 23 using a pump 26, such as a peristaltic pump, orother suitable flow control means. A pick-up conduit 27 extends withinthe reservoir 17 proximate the bottom wall 28 of the reservoir 17 towithdraw the concentrated solution.

A float is positioned within the reservoir 17 and operatively connectedto a float switch 32. The float switch 32 is operatively connected to alogic device (not shown) that controls the spray on and spray off times.This logic device is connected to a spray control means (such assolenoid valve 68) for controlling the flow of diluent to the nozzle 20,in order to maintain a constant level of concentrated solution in thereservoir 17. When the level of concentrated solution in the reservoir17 is below the desired constant level, the float switch 32 iselectrically closed and the logic device will pulse the spray so thatadditional concentrated solution 25 is formed until the float 30 returnsto its desired level.

Examples of suitable logic devices that could be used are individualSSAC solid state recycling timers manufactured by ABB Inc., variouscombinations of SSAC solid state recycling timers manufactured by ABBInc., printed circuit boards, printed circuit boards includingmicroprocessors, programmable logic controllers, logic software residingon a computer CPU, a control device of utilization vehicle 23,mechanical timing cams, or any other suitable logic devices well knownin the art. Any of these logic devices could be used to adjust the sprayon and spray off cycles to pulse the diluent spray and control theconcentration of the dispensed use solution.

The dispenser of the dispensing system 10 is preferably configured andarranged to be mounted upon a mounting surface such as a wall near theutilization vehicle 23. Alternatively, the dispenser of the dispensingsystem 10 could be configured and arranged to be included as a componentof the utilization vehicle 23. The container 12 preferably has a hood34, the upper portion of which contains the housing 35 for the solidproduct 65 and the lower portion of which contains the flow controlassembly 41. The hood 34 is preferably made of a stainless steel ormolded plastic material. Hood 34 preferably includes two apertures 100formed therein which are sized and oriented through the center line ofthe dispenser. The apertures 100 are located at a predetermined heightwithin dispenser, wherein the low product alarm (not shown) detects alow product condition prior to actually running out of product.

Preferably, the low product alarm is enabled when the solid productdrops to a level where the height of the remaining product is equal tothe height of one block 65 remaining in the storage portion 12. Sensorbracket/flange 109 is mounted within container 12, and is configured andarranged to place emitter (not shown) and receiver (not shown) inoperative position relative to the apertures 100. The preferredorientation of the sensors is proximate apertures 100 and forming a linestarting with the emitter, continuing through the centers of apertures100, and ending at the receiver. Those skilled in the art willappreciate that any number of other orientations of the sensors may beprovided in order to monitor the amount of solid product remaining inthe dispenser.

The size and shape of the housing 35 preferably corresponds with thesize and shape of the solid product 65, which is slightly smaller thanthe size and shape of the housing 35, and is preferably cylindrical. Afront panel assembly 39 is attachable to the front portion of the hood34. The housing 35 is preferably made of a clear or translucent plasticmaterial, or contains a clear window, so as to enable an operator tovisually discern the level of solid product 65 contained therein.Additionally, the housing 35 is preferably constructed of a materialthat does not interfere with the low product alarm. Thus, clear ortranslucent plastic is preferred. However, those skilled in the art willappreciate that other types of material might be used which are moreopaque. In that event, either additional apertures or plastic inserts(i.e., translucent or clear inserts) can be provided.

The cover 13 is connected to the upper storage portion 12 by means of ahinge 33. A magnet 66 on the cover 13 controls the opening and closingof a proximity switch 67, and opening the cover 13 causes the proximityswitch 67 to open and to turn off operation of the solenoid valve 68,which controls diluent flow. This provides a safety feature to preventthe operator's exposure to the solid product 65 and the concentratedsolution 25. Grates 36 and 37 are preferably positioned below the solidproduct 65, with the grate 36 having relatively larger apertures andsupporting the solid product 65. The grate 37 is positioned within thehood 34 and has relatively smaller apertures, preferably on the order ofone-half inch in diameter, so as to trap undesirable particles fromentering the concentrated solution.

There is a seal 69 which serves as a divider between the wetted productportion of the dispenser above the seal 69 and the electronic flowcontrol assembly 41 below the seal 69. The seal 69 could be a U-cup, anO-ring, or any other suitable seal. The diluent enters the dispenser'sdiluent supply inlet conduit 19 at diluent inlet point 71. The diluentsupply inlet conduit 19 is provided with a vacuum breaker assembly 70which prevents backflow of the product into the diluent supply line. Theconcentrated solution then exits into the reservoir 17 proximate theoutlet port 40. The concentrated solution is withdrawn from reservoir 17via the pick-up conduit 27 and the pump 26, and then the concentratedsolution is directed to the utilization vehicle 23 via conduit 16.

Proximate the lower end of the dispenser is the reservoir 17, which ispreferably made of a plastic material such as polymethylpentene orpolypropylene and is formed of a single, unitary piece. These types ofplastic materials have resistance to heat and chemicals. Preferably, thereservoir 17 is made of a transparent or translucent material to allowthe operator to see the amount of concentrated solution 25 in thereservoir 17. The reservoir 17 includes a sump (not shown) within thereservoir 17. A sump of the type utilized in dispensing system 10 ismore fully discussed in U.S. Pat. No. 5,100,032, which is herebyincorporated herein by reference.

Positioned within the reservoir 17 is a pick-up conduit 27. Whenconcentrated solution is needed in the utilization vehicle 23, the pump26 is energized and concentrated solution is withdrawn from thereservoir 17 via the pick-up conduit 27. The bottom of the pick-upconduit 27 is positioned slightly above the bottom of the reservoir 17,preferably approximately an eighth of an inch. The pick-up conduit 27 ispreferably made of a polypropylene material. The pick-up conduit 27contains a suitable flow indicator 80 such as one having a ball float81, to enable the operator to visually monitor flow of the wash chemicalfrom the reservoir 17.

The dispenser outlet 40 is positioned directly above a sump, so that theconcentrated solution dispenses into the sump and then overflows intothe reservoir 17. Each dispensing cycle produces approximately 30milliliters (“ml”) of liquid. As used herein, the telin “dispensingcycle” refers to a single activation of the float switch 32. The switch32 may be activated more than once during a single cycle of theutilization vehicle 23. Preferably, the volume of the reservoir 17 isenough for approximately two to five cycles in the utilization vehicle23. By making up a quantity of concentrated solution 25 and storing itin the reservoir 17, the concentrated solution is immediately availablewhenever the utilization vehicle 23 requires it.

Although not shown in the dispensing system 10, the dispensing system 10is preferably modified to include a suitable logic device and a suitablenozzle. An example of a suitable logic device is a SSAC solid staterecycling timer manufactured by ABB Inc., and an example of a suitablenozzle is a Full Jet spray nozzle manufactured by Spraying Systems Co.

Another example dispensing system 100 utilizing a dispenser 106 is shownin

FIG. 3. The dispenser 106 could be any suitable dispenser. A solidproduct 105 is used to create a concentrated solution by pulsing thespray of a diluent through a nozzle 104 onto the solid product 105. Thediluent supply inlet conduit 101 is provided with a vacuum breakerassembly 103 which prevents backflow of the product into the diluentsupply line. The solid product 105 is turned into a concentratedsolution primarily through dissolving at least a portion of the solidproduct 105 into the diluent, which is preferably water, pulsed throughthe nozzle 104. The concentrated solution is stored in the sumpreservoir 107. The diluent is pulsed through the nozzle 104 to increasethe concentration of the concentrated solution by reducing oreliminating the over-spraying and letting the maximum amount of diluentcontact the solid product surface to maximize the dissolution process ofthe solid product 105.

A level switch 102 such as a float switch in the sump reservoir 107 willdetect the absence of concentrated solution, typically due to dispensingof a portion of the concentrated solution into a machine such as awarewashing machine through outlet conduit 110, and the detected absenceof concentrated solution will trigger the timing device 109 to activate.This timing device 109 will open the solenoid valve 102A for arelatively short amount of time (0.1 to 2.0 seconds). This will allow asmall volume of diluent flowing through the diluent conduit 101 tospray, through the nozzle 104, onto the solid product 105. The bottomsurface of the solid product will be wetted and through dissolution aconcentrated solution will be created, which will drip into the sumpreservoir 107. After a delay time (5.0 seconds to 5.0 minutes) thetiming device 109 will re-trigger the solenoid valve 102A, which willspray another pulse of diluent onto the solid product 105. This cyclewill continue to repeat until the sump reservoir 107 is filled withenough concentrated solution to trigger the level switch 102 that thesump reservoir 107 is sufficiently replenished and then the timingdevice 109 will be turned off. An electrical plug 108 supplies power tothe system 100.

In one possible embodiment, when a solid product such as a solid enzymeproduct is used, the spray is pulsed such that during each spray cycle,approximately 50 ml of diluent is sprayed onto the solid product for 0.1to 2.0 seconds to dissolve a portion of the solid product via acombination of impingement force and contact solubility, there is adelay in the spray for 5.0 seconds to 5.0 minutes, and this sprayon/spray off is repeated seven times to create approximately 350 ml ofconcentrated solution, which is directed into a sump. Preferably, thesump is configured and arranged to contain approximately 1200 ml ofconcentrated solution, and approximately 350 ml of concentrated solutionis directed from the sump to the machine. Depending upon the type ofproduct used, the quantity of diluent and the spray on and off timescould be changed to achieve the desired dosing.

A suitable wiring diagram is shown in FIG. 4 illustrating the electricalelements of the dispensing system 100. In this embodiment, a solidproduct such as a solid enzyme product is being dispensed and the floatswitch 102 closes when the concentrated solution is being dispensed orthe level of concentrated solution is otherwise reduced within the sumpreservoir.

In series with the float switch 102 is a cover switch 111, which closeswhen the cover is closed. Also in series with the float switch 102 andthe cover switch 111 is a relay switch 116, which closes when both thefloat switch 102 and the cover switch 111 are closed to turn on a timingdevice 109. The timing device 109 controls a solenoid valve 102A influid communication with a diluent source. Those skilled in the art willappreciate that the timing device 109 only opens the solenoid valve 102A(i.e., starts the spray cycle to allow the spray nozzle to spray thesolid product block) when float switch 102 indicates that the level ofconcentrated solution is reduced within the sump reservoir and closesand when the cover switch 111 is closed, thus closing the relay switch116.

The timing device 109, which controls the solenoid valve 102A, controlsthe timing of the diluent's spray on/spray off. The timing device 109can be set to the desired spray on/spray off times. The timing devicecould be a timing switch, as illustrated, or it could be a circuit boardor any other suitable timing device.

A low product alarm includes an emitter 112 and a receiver 113. Theemitter 112 generates an infrared beam that is received by the receiver113 when the solid product is low, when the solid product no longerblocks the infrared beam. When the infrared beam is received by thereceiver 113, the receiver 113 turns on and provides voltage to operatethe visual and audible indicators 114 and 115, respectively. C1 and C2are termination plugs to connect the dispenser to power and daisy chainthe dispensers together.

An example of possible uses for dispensing system embodiments issurgical instrument cleaning. Although any suitable solid product couldbe used, examples of products that could be used are ASEPTI-Solid AcidRinse/Detergent, ASEPTI-Solid Alkaline Detergent, ASEPTI-Solid Enzyme,ASEPTI-Solid Neutral Detergent, OptiPro Enzyme and OptiPro NeutralDetergent by Ecolab Inc. Preferably, for solid products such as solidenzyme products, solid neutral products, solid alkaline products, andsolid acid products, the concentration of the dissolved solid product inthe use solution is approximately 3.0 to 10.0% by weight of the usesolution.

For OptiPro Enzyme by Ecolab Inc., embodiments successfully controlledthe concentration of the dispensed product and enabled users to increasethe concentration of the dispensed product in the dispenser's sump from2.0 to 4.0% to 3.0 to 6.0% by weight of the concentrated solution byutilizing pulsed spray of a diluent onto the solid product. FIG. 8 showsone embodiment that increased the concentration of the dispensed productin the dispenser's sump from 2.50% to 3.75% by weight of the usesolution by utilizing pulsed spray of a diluent onto the solid productversus a non-pulsed spray. In this embodiment, utilizing a pulsed sprayof diluent increased the concentration of the dispensed product in thesump by 50%. The pulsed spray increases the concentration of theconcentrated solution in the sump because it allows the maximum amountof dilution per unit of diluent. This is accomplished by maximizing theamount of diluent that contacts the solid product and maximizing itsresidence time on that product. Both of these factors assist inincreasing the concentration of the concentrated solution in the sump.

Among other variables, the diluent spray on time and diluent spray offtime (the pulsed spray of diluent on and off) are variables incontrolling the concentration of dispensed product in the dispenser'ssump and providing a consistent dosing of product. Other variables couldinclude product composition, product surface area to be wetted, type ofdiluent, diluent temperature, diluent pressure, room temperature,humidity, and concentration of the concentrated solution or usesolution. It is recognized that there could be additional variables.

It is thought that pulsing the spray of diluent controls theconcentration of the dispensed product in the concentrated solution oruse solution by limiting the amount of excess dilutant added to thedispensed product during the product dispensing process. The product isthen more consistently dispensed and the concentration of the product inthe concentrated solution or use solution is more consistent.Additionally, the concentration of the product in the concentratedsolution or use solution can be controlled by changing either the pulsedspray frequency, the pulsed spray duration, or both pulsed sprayfrequency and spray duration.

Adjustments to pulsed spray frequency and duration can be achievedthrough either a closed loop system or an open loop system. An exampleof a closed loop system would be one that measures the concentration ofthe dispensed product in the use solution and provides the measurementto a control device. If the measured concentration is not equal to apreset target concentration, the control device is able to adjust thepulsed spray duration and/or pulsed spray frequency in order to achievethe target concentration. Examples of suitable concentration measurementdevices include load cells to measure weight loss of the solid product,load cells to measure use solution weight, conductivity cells to measurethe concentration of the dissolved solid product in the use solution,flow meters to measure diluent volume, conductivity sensors to measureconductivity of the use solution, colorimetric sensors to measure colorof the use solution, and ultrasonic sensors to measure a dimensionalchange in the solid product. Additionally, the user could also performtesting to provide closed loop control of dilute product concentration.Examples of suitable tests a user could perform include refractometerreadings, titrations, and test strips. These examples of suitableconcentration measurement devices are intended for exemplary purposesonly and not indended to be limiting. Further, these examples ofsuitable concentration measurement devices could be used individually orin various combinations that are known to those skilled in the art.

An example of an open loop system would be one that does not measure theconcentration of the dispensed product in the concentrated solution oruse solution but rather makes adjustments to the pulsed spray durationand/or frequency to account for changes in environmental conditions.Such a system could adjust pulsed spray duration and/or frequency toaccount for variations in diluent temperature, ambient temperature,diluent pressure, water hardness, or a variety of other environmentalconditions.

EXAMPLE 1

The OptiPro dispenser by Ecolab Inc. was tested using the OptiPro Enzymeproduct by Ecolab Inc. During testing, the concentration in thedispenser's sump increased as the time between dispenser cyclesincreased. Also, the concentration in the sump increased as the amountof the OptiPro Enzyme product removed from the sump per cycle decreased.It was determined that both of these variables could be expressed as thespray on time and the spray off time of the diluent.

EXAMPLE 2

A Design of Experiments (“DOE”) was conducted to investigate the affectsof spray on time and spray off (delay) time on the concentration of theconcentrated solution in the sump of the ASEPTI-Solid and OptiProdispenser by Ecolab Inc. The experiments were conducted using aconductivity analyzer and a data logger to measure the conductivity ofthe concentrated solution and converting the conductivity into a percentweight of concentration. The experiments were run continuously toaccelerate testing, which means that the spray cycle continued to rununtil the block of solid product was depleted. In normal operation, thespray cycle would only run until the sump of the dispenser was at a fulllevel and would not run again until the machine (in this case a surgicalinstrument washing machine) pulled concentrated solution again whichcould be anywhere from immediately to several days.

FIG. 5 shows the DOE. The spray on times used were 0.5, 0.7, and 1.0seconds. The spray off times used were 50, 100, and 150 seconds. All ofthe tests were performed twice except for the mid-point (0.7 seconds/100seconds), which was performed four times.

FIG. 6 shows the weight percentage of the dispensed product in theconcentrated solution for cycle counts for each DOE shown in FIG. 5.Each line represents an individual experiment run. The multiple runsshown in each graph are replicates that were conducted with theconditions noted in the FIG. 6A shows the results for a spray on time of0.5 seconds and a wait time of 50 seconds. 6B shows the results for aspray on time of 1.0 seconds and a wait time of 50 seconds. 6C shows theresults for a spray on time of 0.7 seconds and a wait time of 100seconds. 6D shows the results for a spray on time of 0.5 seconds and await time of 150 seconds. 6E shows the results for a spray on time of1.0 seconds and a wait time of 150 seconds.

FIG. 7 shows an interaction plot of spray on time and spray off (delay)time. The top line shows the results for the 150 seconds spray off timeand the bottom line shows the results for the 50 second spray off time.

The results show that shortening the spray time from 1.0 second to 0.5second increased the sump concentration by 1.0% by weight, therelationship between spray time and sump concentration was linear,increasing the delay time from 50 seconds to 150 seconds increased thesump concentration by 0.35% by weight, the relationship between delaytime and sump concentration was linear, and there was no interactionbetween spray time and delay time.

EXAMPLE 3

As shown in FIG. 8, the graph titled “Pulse Controlled Spray vs.Uncontrolled Spray” shows the sump concentration of a dispensed portionof solid product by weight of the use solution in the sump for a pulsecontrolled spray and an uncontrolled spray.

The OptiPro dispenser by Ecolab Inc. was tested using the OptiPro Enzymeproduct by Ecolab Inc. In the experiments, solid products of the samechemical formula were dispensed with either a pulsed water spray of 0.7seconds on and 20 seconds off or a continuous non-pulsed water sprayduring the product dispensing process. The experiments were conductedusing a conductivity analyzer and a data logger to measure theconductivity of the concentrated solution and converting theconductivity into a percent weight of concentration. As shown in FIG. 8,the “Pulsed Control Spray” yielded a sump concentration approximately1.25% by weight higher than when the same product was dispensed using acontinuous non-pulsed water spray. The light gray line represents theconcentration of the dispensed solution when using a pulsed diluentspray at the spray times described and the dark gray line represents theconcentration of the dispensed solution when using a continuousnon-pulsed water spray. The results show that by using a pulsed spray tocontrol the amount of excess diluent used to dissolve a portion of theproduct, the sump concentration is increased.

The above specification, examples, and data provide a completedescription of the manufacture and use of the composition of embodimentsof the invention. Since many embodiments of the invention can be madewithout departing from the spirit and scope of the invention, theinvention resides in the claims hereinafter appended.

1. A dispensing system, comprising: a dispenser including a cavity and anozzle; a solid product positioned within the cavity; a diluent sourcein fluid communication with the dispenser supplying a diluent to thenozzle; and a logic device controlling spray on and spray off cycles topulse the diluent supplied to the nozzle as a pulsed diluent sprayduring a product dispensing process, the diluent contacting a surface ofthe solid product to dissolve at least a portion of the solid productand create a use solution, wherein the pulsed diluent spray increasesthe concentration of the dissolved solid product in the use solution bylimiting an amount of excess diluent in the use solution during theproduct dispensing process.
 2. The dispensing system of claim 1, whereinat least one of a volume of diluent dispensed through the nozzle, apressure of diluent, a pulsed diluent spray frequency, and a pulseddiluent spray duration affects the concentration of the dissolved solidproduct in the use solution.
 3. The dispensing system of claim 1,wherein the solid product is a solid enzyme product and theconcentration of the dissolved solid enzyme product in the use solutionincreased from 2.0 to 4.0% to 3.0 to 6.0% by weight of the use solutionby utilizing the pulsed diluent spray versus a non-pulsed diluent spray.4. The dispensing system of claim 1, wherein the concentration of thedissolved solid product in the use solution is approximately 3.0 to10.0% by weight of the use solution and the solid product is selectedfrom the group consisting of a solid enzyme product, a solid neutralproduct, a solid alkaline product, and a solid acid product.
 5. Thedispensing system of claim 1, wherein the logic device is a printedcircuit board.
 6. The dispensing system of claim 5, wherein the printedcircuit board contains a microprocessor.
 7. The dispensing system ofclaim 1, wherein the logic device is in a utilization vehicle.
 8. Thedispensing system of claim 1, wherein the logic device is equipped withdiscrete adjustments to control the pulsed diluent spray.
 9. Thedispensing system of claim 1, wherein the pulsed diluent spray iscontrolled through a closed loop control system.
 10. The dispensingsystem of claim 9, wherein the closed loop control system utilizes atleast one of a load cell to measure weight loss of the solid product, aconductivity cell to measure the concentration of the dissolved solidproduct in the use solution, and a refractometer to measure theconcentration of the dissolved solid product in the use solution. 11.The dispensing system of claim 1, wherein the pulsed diluent spray iscontrolled through an open loop control system.
 12. The dispensingsystem of claim 11, wherein the open loop control system adjusts pulsedspray of diluent based on diluent temperature.
 13. The dispensing systemof claim 11, wherein the open loop control system adjusts pulsed sprayof diluent based on ambient temperature.
 14. A dispensing system,comprising: a dispenser including a cavity and a nozzle; a solid productpositioned within the cavity; a diluent source in fluid communicationwith the dispenser supplying a diluent to the nozzle; a logic devicecontrolling spray on and spray off cycles to pulse the diluent suppliedto the nozzle as a pulsed diluent spray during a product dispensingprocess, the diluent contacting a surface of the solid product todissolve at least a portion of the solid product and create a usesolution, wherein the pulsed diluent spray increases the concentrationof the dissolved solid product in the use solution by limiting an amountof excess diluent in the use solution during the product dispensingprocess, wherein the concentration of the dissolved solid product in theuse solution is approximately 3.0 to 10.0% by weight of the use solutionand the solid product is selected from the group consisting of a solidenzyme product, a solid neutral product, a solid alkaline product, and asolid acid product.
 15. The dispensing system of claim 14, wherein thelogic device is a printed circuit board.
 16. The dispensing system ofclaim 14, wherein the pulsed diluent spray is controlled through aclosed loop control system, the closed loop control system utilizing atleast one of a load cell to measure weight loss of the solid product, aconductivity cell to measure the concentration of the dissolved solidproduct in the use solution, and a refractometer to measure theconcentration of the dissolved solid product in the use solution.
 17. Amethod of dispensing a solid product, comprising: placing a solidproduct in a cavity of a dispenser having a nozzle in fluidcommunication with a diluent source, the diluent source supplying adiluent to the nozzle; pulsing the diluent onto a surface of the solidproduct as a pulsed diluent spray to dissolve a portion of the solidproduct and create a use solution during a product dispensing process,wherein the pulsed diluent spray increases a concentration of thedissolved solid product in the use solution by limiting an amount ofexcess diluent in the use solution during the product dispensingprocess.
 18. The method of claim 17, further comprising changing atleast one of a volume of diluent dispensed through the nozzle, apressure of diluent, a pulsed diluent spray frequency, and a pulseddiluent spray duration to adjust the concentration of the dissolvedsolid product in the use solution.
 19. The method of claim 17, furthercomprising utilizing a closed loop control system to control the pulseddiluent.
 20. The method of claim 19, wherein the closed loop controlsystem utilizes at least one of a load cell to measure weight loss ofthe solid product, a conductivity cell to measure the concentration ofthe dissolved solid product in the use solution, and a refractometer tomeasure the concentration of the dissolved solid product in the usesolution.
 21. The method of claim 17, further comprising utilizing anopen loop control system to control the pulsed diluent.
 22. The methodof claim 21, wherein the open loop control system adjusts pulsed sprayof diluent based on diluent temperature.
 23. The method of claim 21,wherein the open loop control system adjusts pulsed spray of diluentbased on ambient temperature.